Pile fabric and method of weaving the same



July 24, 1934. J, SHAW E AL 1,968,003

FILE FABRIC AND METHOD OF WEAVING THE SAME Filed March 1, 1932 2 Sheets-Sheet 1 ATTORNEY July 24, 1934. J. F. SHAW ET AL 1,968,003

FILE FABRIC AND METHOD OF WEAVING THE SAME Filed Mar oh l. 1932 2 Sheets-Sheet 2 lNVEA/ TOR ATTORNEY Patented July 24, 1934 UN STATES PILE FABRIC AND IWETHOD OF WEAVENG THE SAME James F. Shaw and James M. Donnclly, Clinton,

Mass,

assignors to Eigelow-Sanford Carpet 60., End, Thompsonville, Conn, a corporation of Massachusetts Application March 1, 1932, Sei'ial No. 596,032

1 Claim. (01. 139-401) This invention relates to tuft pile fabrics such as carpets and rugs having the pattern on the back, and to a method of weaving the same.

There is a demand for carpets and rugs of the -Axminster type having the pattern on the back and produced by carrying the tuft forming yarns entirely through the fabric to provide a soft wool back in which the pattern is produced, and the present invention relates to an improved pile fabric possessing these features and the method of production.

In accordance with the method of the present invention the fabric is woven face down on a nipper type loom, and has a three plane construction. Three shots of weft are provided for each transverse row of tufts and the shots are positioned one above an upper stuffer warp, a

second below a lower stuffer warp, and a third between the two planes of stuffer warps.

The tuft forming yarns are looped around the "uppermost shot and extend downwardly between the other two shots below the ground structure, so that the upper shots in the fabric as woven become the lower shots when the fabric is finished and placed upon the floor with its pile face up. Two of the three shots just mentioned are disposed at opposite sides of the row of tufts in staggered relation to each other and as a result they support the tufts in an inclined position.

The construction of the present invention produces a good firm ground structure in which the pile forming tufts are firmly secured in place and produce a pile surface of good coverage.

, The construction of the fabric and method of weaving the same will be further understood from the following description when read in connection with the accompanying drawings illustrating the fabric and parts of a loom for weaving the same.

In the drawings:

Fig. 1 is a vertical sectional view through the lay and associated parts of a loom of the nipp yp Fig. 2 is a vertical sectional view through the fabric showing a tuft holding shot in the open shed;

Fig. 3 is a similar view showing this shot beaten up against the tuft forming yarns;

Fig. 4 is a similar View showing the operation of folding the tuft forming yarns about the holding shot;

Fig. 5 shows a shot beaten up against the completed tuft of Fig. 4;

Fig. 6 is a plan view of the upper face of a piece of rug or carpet constructed in accordance with the present invention;

Fig. 7 is a view of the back of the fabric of Fig. 6;

Fig. 8 on an enlarged scale is a longitudinal (w sectional view of the fabric; and

Fig. 9 is a transverse sectional view of the fabric of Fig. 8.

The fabric of the present invention is' well adapted to be woven' on the nipper type of looinj The drawings, therefore, show only the nippers and parts that cooperate therewith in inserting the tufts in the fabric.

The warps employed in constructing the fabric comprise a set of binder warps l0 controlled by the harness 11 and two sets of stuffer warps 12 and 13 disposed in slightly spaced planes and controlled by the harnesses 14 and 15 respectively. The binder warps 10 may be supplied from a single warp beam, and the stuffer warps 12 and 13 from a double Warp beam.

The fabric as woven is advanced in a left hand direction viewing Fig. 1 under the web posi-' tioning plate 16 to the usual take-up roll, not shown. Each weft shot is shown as formed of a pair of weft strands laid by the travel of the weft needle through the shed and these shots are beaten up by the lay 1'7 having the open reed 18.

As above stated three weft shots are inserted E for each transverse row of tufts. These shots are numbered 1, 2 and 3 on the drawings and are inserted in the order in which they are numbered. The pile forming yarns 19 are engaged at one end by the cooperating fingers 20 and 21 of the nippers and are cut to the desired length. The first shot 1 is inserted and beaten up by the lay 17 to the position in which it is shown in Fig. 1. The nippers are then lowered to carry the yarns 19 downwardly through the shed, as shown in Fig. 1, and are then raised to the position in which they are shown in Fig. 2. The second shot 2 may then be inserted and beaten up by the lay, as shown in Fig. 3, to a position to have the tuft forming yarns folded downwardly over this shot, as shown in Fig. 4.

The nippers are then opened to release the ends of the tufts and are preferably moved up against the fell of the cloth to cause the hump 22 upon each nipper finger 20 to tuck the folded tuft inwardly about the holding shot 2. The tuft holding blade 23 provided below the shed is at this time moved upwardly between the fingers 20 and adjacent tufts while the latter are held by the hump 22, to cause this blade to hold the 119 tufts in place while the nippers are being removed. The third shot 3 may now be inserted and beaten up by the lay, as shown in Fig. 5.

During the weft inserting operations just described the harnesses are operated to shift the sheds, as shown, to cause the first shot to be laid above the binder warps but below both sets of stuffer warps. The second shot is positioned below the binder warps but above both sets of stufier warps, and the third shot is positioned above one set of stuffer warps but below the binder warps and other set of stuifer warps.

This causes the weft shots 1 and 3 disposed at the opposite sides of a transverse rowof tufts to lie in staggered relation to each other with the result that when they are beaten up and bound in place by the binder warps 10 they tilt the tufts towards the fell of the cloth and support them in an inclined position, as best shown in Fig. 8.

It is found in practice that the set of stuifer warps 12 lying between the weft shots 2 and S will extend in a straight line, as shown in Fig. 8, while the set of stuiier warps 13 lying between the weft shots 1 and 3 will have the wavy appearance shown in Fig. 8, due to the pressure of the weft shots upon the opposite sides of the stuifer warps 13. This will cause the longitudinal tension of the warps 13 to be somewhat greater than the straight warp 12, when both sets of warps are supplied from the same beam, but

this difference in tension is not suflicient to interfere with the proper weaving operations.

In the construction shown one binder warp l0 and two stuffer warps 12 and 13 are provided between the longitudinal rows of tufts, as will be apparent from Fig. 9.

It will be seen from the foregoing that the three plane pile fabric of the present invention having the patttern visible at the back may be readily woven in a two beam loom of the nipper type.

What is claimed is:

The method of weaving a tuft pile carpet or rug face down in three weft planes separated by stufier warps which consists in each weaving cycle of inserting a weft shot in the lower shed, holding one end of a pile forming tuft and moving the tuft bodily downward to a position entirely below the warp threads, then moving the held end upwardly to a position above the warp threads with the free end below the warp, inserting a holding weft shot in the upper shed, then carrying the held end of the tuft about the holding weft shot downwardly through and below the warp and releasing the held end below the warp threads and inserting a binding weft shot in the middle shed between the planes of the stuifer warps.

JAMES F. SHAW. JAMES M. DONNELLY. 

